Mr. Joseph Mazoff, inventor and member of the Society of Manufacturing Engineers, started his metalcrafts career in Pennsylvania as a young apprentice nine years old in a black smith shop in 1926. In 1938at age 18, competing against more than 300 experienced competitors in their fifties and sixties, Mr. Mazofftook first place in the Pennsylvania state wide tool grinding contest, including twist drill sharpening.

Mr. Mazoff has lectured on Drill Point Geometry in various universities such as Brigham Young and otherteaching institutions in nationwide states such as Texas, Kentucky, Pennsylvania, Ohio, New Mexico andother states.

Mr. Mazoff has also conducted Drill Point Geometry seminars at large machine shops at major industrial plants such as Pratt &Whitney at East Hartford, Connecticut, General Electric at Schenectady, N.Y., The Abex Corporation, The Philadelphia Naval Shipyard& other major installations thathave large machine shops.

Also, Mr. Mazoff authored an 11 page article titled "Choose the Best Drill Point Geometry" which was printed in the June 1989issue of "Modern Machine Shop" magazine. (Reprints of article available by contacting "Modern Machine Shop" magazine).

Back in the Appalachian Mountains where the author started his career in a blacksmith shop, electricity was unknown.Consequently, when drilling holes manually with 1-1/2" diameter drills, such drilling was painstakingly slow, requiring much time,patience and physical effort. Therefore, through experimentation; it was established that once a conical (conventional) surfaced drillwas ground with a flat surface (multi-faceted point); it produc a linear chisel which required 150 percent less thrust than a conventionaldrill. However, as manual proficiency to grind multi-faceted points declined down through the years, such points declined accordinglybecause they are extremely difficult to grind by hand. However, due to the recent advent of NC machinery that demands self-centering points, multi-faceting has been revived to meet the demand.

As you will note in the pages that follow, a most important feature of multi-faceting is the wide variety of drill points it permits tobetter serve the craftsmen's needs; especially in this modern age of exotic metals. Exotic metals are indispensable, compelling ourcraftsmen to adapt to more up to date Drill Point Geometry. Hence, the purpose of this article is to inform and update craftsmen onthis superior type of drill point geometry with its greater variety of geometrical patterns for more advantageous applications. Otheraspects of drill point geometry will be covered that are rarely or ever covered in print sincepractically all drill point data deals with the same meaningless information telling craftsmenthat "It's important to Keep Drills Sharp." Instead, this article elaborates on how to sharpendrills for best results and to clarify long standing unproductive misconceptions. The drill is themost important, least understood, and most neglected of all cutting tools, and, we accept drillpoint standards, based on inflexible precedent rather than logical deduction andexperimentation. As an example, craftsmen assume that the 118? point is a good compromiseor general purpose point for drilling a variety of different metals and this erroneous informationappears in machine shop textbooks. Varying the point angle has nothing to do with cuttingaction. The 118? point is pure myth. In reality, a compromise between high and low lipclearance angles is the determining factor for a general purpose cutting tool, NOT the (non-cutting) point angles. On the other hand, when lip clearance angles are compromised, we arebucking the "laws of physics". Meaning that if we compromise the cutting edge of an axe, itwill do a poor job to either shave a beard or split a log. Thus, lip clearance angles must beadjusted to the metal's degree of hardness and machineability. GENERALLY, less clearance forhard metals and increased clearance for softer metals accordingly.

As to drill point angles, note in fig. A, that the full length of the cutting lips are involved in cutting action while in fig. B, only 64percent of the lips length are involved in the same depth of parent metal. Maximum rate of penet tion into metal occurs only whenthe full length of the cutting lips are involved in the material. Thus, the more blunt the point, the sooner the lips are involved in fullcutting action. Although figures A and B have the same width denoting the same drill diameter, the more blunt point of fig. A hasshorter over all cutting lip lengths than fig. B's. This means that fig. B would drill the same size hole but with longer lip lengths and awider ribbon, thus creating more torque for the same size drill. Specifically, the lip length of a 1" diameter drill with 140? includedangles will measure 9/16" per lip and the same drill with 118? included angles will measure 39/64" length per lip. Multiplied by bothcutting edges, the 1" drill with 118? included angles is the equivalent of drilling with 3/32" larger diameter drill. With larger drills, thespread is markedly increased.

Note in Fig. D that the chisel's profile is flat (linear) running straight across the drill, forming sharp acute angle corners where the chiselends join with the web surface. When drilling a hole, the chisel's full length contacts metal and the chisel's corners simultaneouslyaugurs into the metal, immediately producing chips. Furthermore, the flat ground facets produce a prounounced sharp edge on thechisel as seen in Fig. C. As a result, the chisel has outstanding extruding properties permitting less thrust, less heat, and greaterproductivity than the conventional drill. The conventional drill has a bow shaped (non-linear) chisel which literally wears a saucershaped depression in the metal for the full depth of the hole. In stainless steel, frictional heat is sufficient to turn such a drill blue,generating temperatures over 1000?. With rounded surfaces on each side of the conventional drill, it has poor extruding properties,calling for high thrust pressure.

DRILL POINT GEOMETRYby JOSEPH MAZOFF

In drilling operations, the by-products of rotational energy is chips and heat, either highheat and less chips or less heat and more chips. Multi-faceted geometry generates the leastamount of heat of all the drill point patterns. In comparing two drills of the same diameter,the multi-faceted drill features 150% less thrust and 70% less heat than a conventional drill.

Four faceted drill points consist of separate cutting lip (primary) and secondary heelclearance (relief) facets (fig. E) and extending the secondary facets to the midway point ofthe chisel produces the apex (point) (fig. F) at the center of the chisel's long axis. As a result,it produces a self-centering point, eliminating center punching and pilot holes. It won't walk,and is the most accurate of all points. It's especially applicable to NC machines, matchedholes on dies and can be ground on the largest of drills. Primary facet angles is determinedby the nature of the material being drilled while secondary facet angles are at 20?.

The 6 faceted drill with secondary point angles (SPA) is the most durable of points, but least understood and utilized. The 5thand 6th facets form secondary drill point angles (fig. G & H). The weakest area of the point is the outside cutting lip corners whichare also exposed to the greatest amount of stress and travel. Consequently, drill points break down most frequently at thosecorners. Secondary point angles reduce those acute angles. (fig.H) to reduce corner breakdown, and consequently, reducesregrinding frequency which increases drill life. By actual tests in our shop, we have obtained as high as 700% more holes than aconventional conical ground At the Ford Motors Engine Plant in Ohio, the computer indicated an expected life cycle of 8000 holes.However once the same conventional drills were reground with the fig. H chamfered point, the computer printout showed aproductivity of 31,057 holes. In compliance with my recommendation that Ford Motors reduce the cutting clearance, productivityincreased to 37,100 holes at which time the drilling project was completed; but the drills were still in excellent condition. Theattributing factors for such a sharp increase in productivity were the flat grind combined with the chamfered corners in G and H.Metal being drilled was cast iron. Secondary point angles produce secondary cutting lips that angle toward the heel corners (fig.G). As the drill rotates, the back of the secondary lips cuts metal with a slicing action which further reduces lip corner breakdownand less heat, drill torque, and less binding as the drill exits from the hole. This point is ideal for core holes and to material,producing burr free holes. There is also greater hole accuracy since the secondary point angles offer a self-seating, reaming actionthat resists lateral pressures. In addition, this point has good chip breaking properties since the primary and secondary cuttingedges in fig. G, produces an angular formed ribbon that breaks readily as it curls against the flute surfaces. The amount of degreesthat's ground on the secondary point angles is determined by what angles were ground for the primary point angles. The rule tofollow is to split the angles evenly. As an example, if one side of the primary point angle is 67?, then the secondary would be halfof or 33-1/2 and etc. This splitting of the angles is best seen in fig. H. However, there are some exceptions in splitting the anglessuch as plastics, in which case, the secondary angles should be decreased (more spearshaped). As to lip clearance angles ofsecondary cutting lips, they are generally the same as the primary lip clearance angles SPA can be added to all other points forincreased accuracy and durability.)

The conventional split point (CSP) is highly productive but is limited since it cannot beutilized on drills beyond 1/2" dia. In addition, the neutral corners of the CSP impedes theescape of the chips resulting in a weld bead that has a tendency to neutralize the advantagesof the CSP. Furthermore, the CSP is a most exacting and critical geometry to re-grind at thelocal shop level. However, the Modified Split Point (MSP) (figs. I and J) doesn't have theshortcomings of the CSP since re-grinding the MSP is not a critical operation. Furthermore,the MSP is a far more productive point. In fig. J, note that the webb's notch has a positiverake, resulting in secondary positive cutting edges up to the chisel, thereby increasing drillingefficiency. Also note that the secondary cutting edges blend into the primary cutting edges with less acute angled corners, therebypermiting the MSP to be ground on drills up to 3" in diameter. The chisel length (fig. I) can be reduced accordingly to a length of0.050" for 3" diameter drills down to 0.010" for 1/4" drills, resulting in unparalelled extruding properties; permitting the cuttingedges to bite deeper into the metal for thicker chips. The MSP produces a self centering drill which eliminates pilot holes even for3" diameter drills. Notches are ground parallell to the flute angles (fig. J) which permits self cleansing notches, allowing chips toflow freely up the flute. With the notch on the opposite webb angling diagonally up and away from the other notch, the webbthickness is not compromised, thereby permitting a stronger point that allows increased thrust to drill holes more rapidly. As aresult of these features, the MSP developed by the author is superior to the MSP produced by Renault-Peugeot or other sources.

Using the Swedish IMA drill press with controlled feed and speed settings, our company confirmed that the Modified SplitPoint produces 3 to 5 hundred percent more holes than the Conventional Split Point and 7 to 8 hundred percent more holes thannew factory ground conventional drills. Written testimonials from other reputable soueces confirms these findings. Modified SplitPoints also generate the least amount of heat of all twist drills. An article entitled "Pointing Towards High Drilling Rates" publishedin the June 1982 issue of Modern Machine Shop magazine, page 85, showed a thrust chart with the following information. At afeed rate of 0.027 IPF and four different drill points being the same diameter of 1.57 inches, the conventional drill required the mostthrust, over 5,000 pounds while the MSP Renault-Peugeot point (R.P.) required the least amount of thrust, 2,000 pounds to drillthe same size hole. However, the MSP developed by Mr. Mazoff requires 165% less thrust than the RP point to drill the same sizehole.

In sharpening the MSP, chisel lengths are varied, ranging from 0.050" on a 3" diameter drill down to .010" on a 1/4" diameterdrill. The rake across the webb (the notch) can be varied ranging from 5? positive for the softer materials to a 5? negative for thehardest materials. The MSP is especially outstanding for stainless, inconel, titanium and other difficult metals. The MSP is alsoself-centering, eliminating pilot holes.

The Dubbed drill (fig. K) can be used for drilling many materials in addition to brass andcopper. Conventional twist drills have maximum positive rake (angle or pitch) of the flutesat the outer extremes of the cutting edges and gradually approaches a neutral or slightlynegative angle at the webb center, depending on the drill's helical nature. This results incutting edges with variation in cutting action, reduced to it's minimum in the vicinity of thedrill's center and excessive at the outside lip corners where there is the greatest degree ofrake and rotary travel. This situation puts the cutting edges in the OD area undertremendous stress and is a primary reason for lip corner breakdown. However, dubbing theflute surfaces produces uniform rake angle across the full length of the cutting edges (fig. K), thereby increasing cutting action inthe central area of the drill where it is normally minimal and gradually decreased toward the OD where it is normally excessive.This results in more equalized distribution of cutting action across the lips full length, thereby reducing corner breakdown whilemarkedly increasing drilling efficiency. In fig. L, note the dubbed cutting edges have reduced the chisel's length. Therefore, adubbed drill is also self centering, eliminates webb thinning, center punching and pilot holes. The notches on this drill also angleaway from each other like the MSP to preserve the thickness of the webb's central surface for greater strength against crushingforces.

Fig. M and N are cross sections of dubbed rake angles, but note that the lip relief anglesremain unchanged in both figures. However, the cutting edge in fig. N is producing thethicker chip because of an increased rake of the dubbed flute surface. Such geometryproduces a planing action due to low lip relief angle which reduces hogging-in and drillchatter, thereby increasing productivity and accuracy. A reduced chisel as in fig. L andincreasing or decreasing the rake accordingly permits a dubbed point to drill hard or softmetals, bakelite, fiberglass, plexiglass, copper or brass. When drilling very soft copper orbrass, use 5? negative rake and as metal hardness increases, adjust the rake accordinglytowards a positive rake angle.

Drills with unequal lands are quite common and they are simply IMPOSSIBLE to grind properly since the cutting lips are notat opposite positions of 180? from each other. Needless to say, such drills, even new ones will NOT drill efficiently or accurately.Equally deplorable and common are drills with unequal flute to flute surface configurations. However, dubbing such drills willdress out the differences, therefore leaving dubbed lips at a precise opposite 180? position from each other and uniformconfiguration of flute to flute surfaces. An additional problem is the numerous flute surfaces that have rough serrated surfacesthat results in saw toothed cutting edges that break down more readily. Dubbing also solves this problem, producing smoothuniform surfaces on such drills, thereby increasing lip life.

For stainless steel, drills are ground with 140? included drill point angles and 10 to 12? lip relief angle facets which assuremore positive cutting action while the blunt 140? point assures maximum lip involvement in the earliest possible time. The key todrilling stainless steel is to avoid work hardening by obtaining maximum cutting action in minimum time. The recommended pointis Fig. I in page 2 and secondary point angles (Fig. H, page 2) to strengthen the lip corners. The secondary cutting lips constitute10 to 15 percent of the lips overall length. The notch (Fig. J P2) may vary from 5?positive notch for soft stainless, neutral for semi-hard and 5? negative for hard exotic metals.

Plastics are notorius to drill; demanding the highest degree of drill point accuracy; and especially the most blunt of all points.1/8" thick plexiglass was drilled at 35? Farenheit above zero with a different variety of drill diameters and point angles. Beginningwith 80? included angle drill points, the material would shatter every time as drill point began to emerge through the bottomsurface of the material. As the point angle was increased (more blunt), destruction of the plexiglass was reduced accordingly. At134?, breakage was markedly reduced. At 142?, there was no breakage. Chipping around the bottom shoulders of the hole asthe drill exits was eliminated with secondary point angles (Fig. I, page 2). In this case, the secondary cutting lips were 20 percentof the overall lip length. Therefore, it was concluded that the recommended 60 to 80 included angle points were the mostdestructive in drilling plexiglass. With such a spear shaped point, when the drill begins to emerge from the materials, a smallirregular circular shaped hole with feathered edges develops in the bottom surface. Consequently, spear-shaped cutting lipswedge into the feathered edges at right angles, causing a binding and locking action that instantaneously shatters the material.On the other hand, a blunt point with less wedging action exits more gradually with its cutting lips more parallel to the featherededges. In essence, the recommended 60 to 80? point standards for drilling plastics have no scientific merit. In the final analysis,the most effective point consisted of 144? included angles for the primary point, 80 to 85? included secondary point angles, 4 to5? primary clearance angle facets and 20?secondary heel clearance facets. (Twenty degree heel clearance facets automaticallyground whenever primary angle facets are 8? or less). The general rule is that as the primary facet angles are reduced, thesecondaries are increased accordingly as in figure P, page 4. Thus, blunt drill points with lip clearances adjusted for specificmaterials have equal application on hard and soft ferrous, non-ferrous, some non-metallic materials.

Excessive lip clearance is extensively practiced througout the U.S. in fragile material, it causes severe hogging in and materialdestruction. Also, it produces over-sized holes and is a primary cause for reduced cutting edge life. Such excessive clearance isdue to the tendency to incorrectly view the drill as shown in Fig. D. (P 1). In viewing that drill, most readers would insist that thedrill has little or no lip clearance. However, it's an optical illusion since that drill actually has a high clearance of 15?. Never theless, practically all craftsmen try to determine lip clearance by looking directly into the drill as in Fig. D. In doing so, one is lookinginto a compound angle, looking at the overall surface of the drill rather than a side PROFILE of the cutting edge itself.

HOW TO VIEW LIP CLEARANCE ANGLE. An eyeball method that's fast and positive is to read the chisel line angle (chisel'slength). If the chisel's line angle is on a vertical plane pointing to 12 o'clock (90? in relation to the cutting edges on a horizontalplane, lip clearance would be zero. But as lip clearance is gradually increased, the chisel line inclines diagonally to the rightaccordingly towards 1 o'clock. (fig. 0). Therefore, by paralleling the cutting edge with a protractor, a reading of 110? of the chiselline angle denotes approximately 5? or low clearance; 120? indicates 8? or medium clearance, 130? indicates 11? or highclearance, and 135? indicates extra high clearance. With some practice, a glance will instantly reveal the clearance status quiteaccurately without a protractor.

HOW MUCH CLEARANCE DO WE NEED? Using a two faceted drill as fig. O forexample, slight impingement about 1/32" in size first occurs at the rear outside heelcorners when constant lip clearance is reduced down to 7?. At 5?, impingement isapproximately 1/16" in size, and further clearance reductions result in a triangular shapedimpingement radiating primarily toward the lips and secondarily towards the chisel.Therefore, a small secondary facet (fig. P) is required only when the constant clearance is8? (medium clearance range) and the secondary facet size is increased gradually towardthe cutting edge (fig. G P1), as the primary lip angle is reduced accordingly down to the 5to 3 degree range (low and extra low clearance range).

In selecting the correct lip clearance angles, it requires analyzing the material's machinability, hardness, brittleness, fragility,etc. Since drill chatter and hogging in can be detrimental to both drill and material, it obviously demands reduced clearance in afragile or hard material. Reduced clearance produces a smoother and more accurate hole while permitting increased drillingspeeds to compensate for chip thinness.

A FINAL NOTE ON PRODUCTIVITY: In the early fifties, the author was involved in introducing the dental profession to highspeed air turbine mandrels that allowed dentists to drill out tooth decay at least 500 percent faster than with the former gear drivenmandrels. In short, the metal fabricating industry is behind the times, losing countless millions of dollars due to low speed drillingoperations. High speed and flood cooling is the ultimate answer for high productivity. However, drill presses must be in topcondition with absolute accuracy. Readers should be forewarned that factory ground drills generally do not meet such accuracyrequirements due to mass production; and also applies to various drill sharpeners that lack proper mechanical design andconcepts to assure the extremely high degree of accuracy. In drilling operations, speeds 300 to 400 percent higher thanrecommended in the handbooks can be achieved. Handbooks must recommend lower speeds because of inaccurately, manuallyresharpened drills and run-out on worn drill presses.

Spades blades utilize the same geometry of this article and they are fabricated with more blunt points, therefore offering theusers the advantageous features as reflected in this article. The spade blade has numerous superior advantages over twist drills;such as permitting a more open channel for the coolant to reach the cutting area in the hole, elimination of woodpeckering in deepholes and excellent chip breaking properties. And since the spade blade holder is a thick walled tubular structure, it possessessuperior torque properties, therefore permitting much deeper holes than twist drills. In addition, one holder can accomodate upto eight different sized blades, thereby drastically reducing both cost and storage space to a fraction of eight twist drills. And sinceholders are produced in different lengths, the operator has more flexibility to meet specific drilling requirements. A primaryobjection to greater use of spade blades has been the expensive and time consuming resharpening operation. However, theChamp drill grinder (available through ICS Cutting Tools) rapidly sharpens spade blades. In most American machine shops, drillsare in the most deplorable condition of all cutting tools, namely bent drills, with excessively thickened webs, large nicks and chipsof the cutting edges, badly worn margins, scored and distorted shanks and cheap quality drills. It should be noted that top qualitywork demands top quality drills. Top quality drills are all the more important, considering that drilling operations lead all otherfabricating steps. Drilling operations exceed milling, bending, stamping, turning and all other operations. It's impossible tocalculate monetary loss as a result of unproductive drills in our nation's metal working shops. This monetary loss is compoundeddue to scrapping costly finished work pieces, nullified by the final step, the drilling operation, further compounded by a generallack of knowledge on drill point geometry; thereby failing to take advantage of the best geometrical patterns. The drill is simple inappearance but complex in function.

ICS Cutting Tools carries the "CHAMP" Multi-Faceting machine that grinds all the points listed in this article and though it'sunequaled in price and drill capacity, readers are urged to compare the CHAMP against all other multi-faceting machines to satisfythemselves. Be sure to compare the price, capacity, and ask competitors if they can grind the positive notched Modified SplitPoint.

ICS CUTTING TOOLS, INC. • 511 Main St. • Casco, WI 54205 • www.icscuttingtools.com • info@icscuttingtools.com